Roof and wall surface



Feb. 4, 194-1. R HT V 2,230,555

ROOF AND WALL SURFACE Filed Jan. 16, 1959 2 Sheets-Sheet 1 O O O .O 0

Patented Feb. 4, 1941 UNITED STATES PATENT OFFICE 6 Claims.

This invention relates to surfacing of walls or roofs, and is more particularly directed to a surface structure of metal foil and to the manner of supporting such foil to form a surface. This invention is an improvement over the roof and wall surface of Letters Patent No. 2,081,191, granted to me May 25, 1937.

My invention deals primarily with the architectural surfacing of a roof or wall employing thin metal sheeting or foil so applied to the structure as to provide a surface of desired artistic appearance and configuration which is of great durability and wherein a plurality of sheets are utilized and connected in such a manner as to resist the destructive effects of the elements and is also of a water-proof character.

It is an object of this invention to provide a simple, inexpensive means for the surfacing of roofs, walls, or the like, with sheets of metal foil which are so connected together as to eliminate leakage of water at the points of connection of the sheets of foil.

Another object of this invention is to provide a simple, inexpensive form of foil supporting member which may be easily and readily secured in position to form a roof or wall surface and to retain the metal foil surface thereon.

Another object of my invention is to provide a means of applying to a roof, sections or sheets of metal foil to give the roof or wall surface the desired or required ornamental appearance and wherein there is formed at the joining portions of the sheets a means for preventing water from leaking between the joints of the said foil sheets, and provide a self centering key for simple and rapid application of one sheet to the other, which means includes the embossing of one or both of the sheets at their points of joinder so as to form a free air passage transversely of the sheets operative to break the effects of capillary attraction operating to draw moisture or water between the sheets at their points of connection.

Other objects and advantages of this invention it is believed will be apparent from the following detailed description of a preferred embodiment thereof as illustrated in the accompanying drawings.

In the drawings:

Figure 1 is a perspective view of a roofing construction embodying my invention.

Figure 2 is a sectional edge view of the roofing construction embodying my invention.

Figure 3 is an enlarged fragmental sectional View illustrating the incorporation in my invention of the means for connecting sheets of metal foil together so as to prevent capillary attraction causing leaking between the sheets of foil at their point of connection.

Figure 4 is a fragmental elevation of a portion of the sheet of foil as embodied in my invention.

Figure 5 is an enlarged fragmental sectional view taken substantially on the line 55 of Figure 4, and illustrating a fragment of a second foil sheet in edge to edge overlapping relation.

In the preferred embodiment of my invention as illustrated in the accompanying drawings, the surface embodying my invention is illustrated as composed of interlocking cores l, which form a continuous support for the sheets of foil 2, which form the element-resisting water-excluding surface. The sheets 2 of foil are sheets of thin metal, such as copper foil. This foil is formed in sheets which, while they may have considerable breadth and length, are not generally of sufficient size as to permit the formation of a roof surfacewithout joining the sheets together.

The interlocking cores I are formed of any suitable or desirable material such, for example, as are any of the well known insulating materials or any other material which may be desired. They may be cast or fabricated in any desired or preferred manner, depending upon the material utilized for their formation. They may be of sufficient thickness so that they are of a selfsustaining character when. positioned upon the surface between the rafters or purlins, or they may be of relatively thin character and be supported over the structural members forming the roof or wall surface as illustrated in. the patent heretofore granted, No. 2,081,191. These core members are preferably formed of material having heat insulating properties and are formed with interlocking front and rear ends 3 and 4.

The ends 3 are formed with channels 5 which extend the length of the forward edge of the cores a distance spaced rearwardly from the front edge 6; The channels 5 may be of any suitable configuration but are preferably formed to avoid the formation of sharp edges therein into which the ends of the sheets of foil 2 might be crimped or scored.

As illustrated, the core members I are formed of insulating material or wood and the channels 5 are either cast in the formation of the insulating material or may be routed if wood is used to form the cores I.

The forward edge 6 of the cores l terminates at a tension-applying cantilever foot I, the lower face of which is elevated above the supporting base 8 of the core I. The complementary rear end 4 of the core I is formed at the rear edge of the core I with a longitudinally extending rib 9 of configuration complementary to the configuration of the groove 5. As herein illustrated, the groove 5 and rib 9 are of substantially uniform curved formation. The rib 9 is raised above the foil supporting surface In of the core.

In applying the foil material to the cores I, a sheet of foil is applied on the surface ll] of the first core I and the forward edge of this sheet 2 is secured within the groove 5 through the use of any suitable form of securing means; or the sheet of foil 2 may be merely wrapped around the forward end of the core I over the forward edge 6 and foot section I to extend into the groove 5. The core I may then be secured in position in any suitable manner as, for example, illustrated in my Patent No. 2,081,191 heretofore referred to, adjacent the forward end thereof, and the sheet of foil 2 may be then laid back upon the surface of the core. The rear end of the sheet of foil is then laid over the rib 9 and pulled in tension so that the sheet of foil is held taut between the forward end of the core and the rear end thereof, at which time the sheet of'foil will be in a position substantially as illustrated in the dotted line I I, i. e., raised above the surface [0 of the core I. .The rear edge of the foil may then be secured in position over the rib 9 by the use of any suitable form of fastening means such as nails 30 which are passed through the rear edge of the foil 2 through the rib or tongue 9 of the core I and into the supporting structure upon which the cores are applied.

The second sheet of foil 2 is applied with the first sheet of foil to the rib 9 of the first core. The selvaged edges 20 are overlapped and the two sheets of foil are secured in position thus in predetermined alignment. Spaced holding means such as nails 30 may be used. The second sheet of foil 2 is then folded over the cantilever hook end 6 of the second core I. As thus applied, the forward nose or foot 1 of the core I forces the foil 2 under added tension downward toward the supporting surface I!) of the core I, or from the position illustrated by the dotted line H to the position illustrated in full lines. This construction then forms a cantilever hook of relative flexibility permitting expansion and contraction, depending on the degree of resiliency of the material of which the core is formed. Any suitable material may be used, but I prefer to use a material of high heat insulating characteristic as possessed by some composition boards.

While this action produces additional tension in the sheet of foil 2, it ordinarily does not actually force the sheet of foil 2 into permanent contact with the surface IU of the core I, but leaves a dead air space between the surface [0 and sheet of foil 2. This dead air space has a considerable heat insulating value against the heat which is transmitted to and picked up by the sheet of foil 2 under the direct rays of the sun permitting the sheet of foil 2 to act to a considerable degree as a heat radiating surface and because of dead air space, the heat transfer between the under surface of the sheet 2 to the core I is very low. The sheet 2, however, is held in close enough proximity to the surface H) by this method so that the surface I0 substantially supported the sheet 2 throughout its length against the effects of any object falling on'or passing over the roof surface, avoiding the poss b li y o t e she t bei g'punctured or perforated because supported away from the surface The foil 2 on the second core is then applied over its surface in substantially the same manner as described in connection with the application of the sheet of foil to the first core, and this action is repeated until the roof or wall surface is completed.

It will be obvious from the foregoing that the forward edge 6 of the cores I act to define the stepped elevation of the roof surface as finally applied. These surfaces 6 may be made of any suitable or desirable configuration desired for the ornamentation or textural appearance value of the completed roof or wall structure.

In addition to the foregoing, it will be obvious that the metal foil sheets may be embossed in any suitable or desirable manner as generally indicated at 12 in order to produce the desired effect of light and shade upon the surface when completed, or to give to the surface any desired pattern for the required artistic appearance of the completed structure.

In order to avoid all possibility of leakage of water between the metal foil sheets 2 where they are held together between the ribs or tongues 9 and channels or grooves 5, and particularly to break any capillary force tending to draw water through this joint, I have found that by embossing the forward ends of the overlying foil sheet 2 or the rear ends of the underlying foil sheet 2 at the forward portion l3 of the curvature defined by the rib 9 and channel 5, that I am enabled to form at this point a longitudinally extending free air channel M or a plurality of such channels l4, depending upon the particular character and location of the embossing, which free air channel disrupts the force of capillary attraction stopping water from passing between the sheets when it reaches this free air channel or' channels.

In order to accomplish this result, it is only necessary that one or other of the meeting ends of the sheets of foil be formed with a plurality of rows of embossed elevations or nobbins 15 which maintain one sheet of foil away from the other sheet at this particular point. It is of course obvious that this channel may be formed at any point along the overlapping sections of the sheets of foil 2 from the forward edges 6 of the core I to or around the rib 9 formed at the rear of the core I.

In order to center the sheets of foil together at their overlapping edges and to facilitate aid in securing the same to the core members, a centering selvage edge 20 is formed at each edge of foil sheets. The selvage 20 extends longitudinally of each foil sheet and is herein illustrated as a longitudinal rib. These ribs interfit and the securing means such as nails or the like are passed through the selvage to preliminarily anchor the foil sheets under intitial tension.

In the interfitting cores embodying my invention the rear edge l6 of the rib 9 and the corresponding advanced edge lBa of the channel 5 are so formed as to provide an angle lock. By angle lock I refer to the inability of the upper core 2 to raise more than the slight distance permitted by the clearance allowed between the edges 16 and |6a due to the downward and forward tapering of these edges. Thus when the forward edge of the upper core 2 tends to raise away from the lower core, the angled edge l6a engages the edge I 6 and is stopped in upward movement.

It will be noted that in the disclosure of my invention as herein made that the foil 2 is applied directly to the cores I without the interpositioning between said cores and the foil of roofing felt or paper as generally indicated in the patent heretofore granted to me, No. 2,081,191. It will be obvious that this roofing felt or paper may or may not be used as desired.

Having fully described my invention, it is to be understood that I do not wish to be limited to the details herein set forth, but my invention is of the full scope of the appended claims.

I claim:

1. A surface including overlapping core members, the core members having complementary interfitting securing means at their overlapping sections, one of which securing means includes a projecting rib, relatively thin sheets of metal or foil applied to the core members with the overlapping edges of the foil members passing over the said rib and being fastened to prevent motion of said foil relative to said rib, the length of foil covering the core member having said rib being insufficient to allow the foil to follow the contour of said core member and rib whereby the sheets of foil are held in tension with relation to the core members to maintain dead air spaces between the under surface of the sheets of foil and the upper surfaces of the cores.

2. A surface including a plurality of overlapping core members having at their overlapping sections curved interfitting channels and ribs, and tension feet adjacent said channels, relatively thin sheets of foil applied over the core members with overlapping edges passing over the curved ribs in said channels, means for securing the said overlapping edges together and to said core members at the rear sections of the lowermost core with the lowermost sheet of foil tensioned between said securing means and the opposed edge of said core whereby the tension foot of the uppermost core acts to tension the said lowermost sheet of foil by urging the same toward the surface of the lowermost core whereby an air space is maintained between the surface of the lowermost core and the sheet of foil applied thereto.

3. A surface including a plurality of overlapping core members having at their overlapping sections curved interfitting channels and ribs, and tension feet adjacent said channels, relatively thin sheets of foil applied over the core members with overlapping edges passing over the curved ribs in said channels, means for securing the said overlapping edges together and to said core members at the rear sections of the lowermost core with the lowermost sheet of foil tensioned between said securing means and the opposed edge of said core, whereby the tension foot of the uppermost core acts to tension the said lowermost sheet of foil by urging the same toward the surface of the lowermost core whereby an air space is maintained between the surface of the lowermost core and the sheet of foil applied thereto, and the overlapping sections of said core members being provided with interengaging sections whereby substantial relative vertical movement between said cores is prevented.

4. A surface including upper and lower overlapping core members, said lower core member having an upwardly extending rib adapted to fit into a channel in said upper core member, relatively thin sheets of metal or foil applied to said core members and fastened to said rib and to each other, the length of foil applied to said lower core member being insufficient to permit said foil to conform to the contour of said lower core member, a cantilever tension foot on said upper core member adjacent said channel, said tension foot engaging the foil on the lower core member to produce tension therein and thereby to provide an air space between the surface of the lower core member and the foil applied thereto.

5. A surface according to claim 4 in which a multiplicity of spaced rows of studs is embossed near the edge of one of said sheets, whereby the other said sheet is held away fromsurface contact with said first-mentioned sheet to form free air channels between the embossed studs.

6. A surface including upper and lower overlapping core members, said lower core member having an upwardly extending rib adapted to fit into a channel in said upper core member, relatively thin sheets of metal or foil applied to said core members and fastened to said rib and to each other, the length of foil applied to said lower core member being originally insufficient to permit said foil to conform to the contour of said lower core member, a cantilever tension foot on said upper core member adjacent said channel, said tension foot engaging the foil on the lower core member to produce tension therein, the portion of said upper core member adjacent said channel and opposite said tension foot engaging the lower core member to form a fulcrum for said cantilever tension foot.

LLOYD WRIGHT. 

